Role Purpose:
Own in-process quality for medium and power transformers (33–400 kV), ensuring products meet applicable standards, customer specifications, and Ayr Energy's Quality Management System (QMS). Lead stage-wise quality controls across core, coil, tanking, assembly, oil processing, and final tests to achieve first-time-right builds, reduce rework, and elevate
customer satisfaction.
Key Responsibilities:
1. Quality System & Documentation
• Create and maintain Control Plans, Inspection & Test Plans (ITP), stage checklists, work instructions, and traveler/route cards; enforce hold/witness points.
• Own NCR/CAPA—facilitate structured root cause analysis (5-Why, Fishbone), implement fixes, and verify effectiveness; drive defect prevention.
• Maintain device history records, test certificates, as-built dossiers, and customer documentation packs for shipment and FAT.
2. Supplier & Customer Interface
• Qualify and develop suppliers for critical items (CRGO, copper, bushings, OLTC, radiators, tanks); conduct audits and PPAP/FAI where applicable.
• Lead customer stage and final inspections (FAT), coordinate third-party inspections/test labs, and close observations promptly.
3. Data, Metrics & Continuous Improvement
• Track FPY, rework/repair hours, supplier PPM, test bay failures, and COPQ; publish weekly/monthly dashboards.
• Apply 7 QC tools, MSA (GR&R), process capability (Cp/Cpk/Pp/Ppk), and SPC to stabilize and improve processes.
• Run kaizens to reduce defects (e.g., oil leaks, winding shorts, paint defects) and cycle time at critical stages.
Compliance & Standards
• ISO 9001:2015 QMS; ISO 14001 and ISO 45001 (EHS) – adhere to procedures and participate in audits.
Qualifications & Experience:
• Education: BE/B.Tech or Diploma in Electrical/Mechanical Engineering (Electrical preferred).
• Experience: 8–15 years in transformer manufacturing quality; at least 5 years hands-on in-process/stage inspection and test bay exposure for 66 kV+ class.
• Certifications (preferred): Six Sigma Green Belt/Black Belt, ASQ CQA/CQE, NDT Level II (VT/PT), Lead Auditor (ISO 9001).
Skills & Competencies:
• Strong knowledge of transformer construction, drawings (GA, core/coil, schematic), tolerances, and insulation systems.
• Proficiency with electrical tests (TTR, WR, IR/PI, tan δ/PF, SFRA, AC withstand) and interpretation of results.
• Hands-on with metrology and torque tools; ability to set up gauges/fixtures and verify special processes.
• QMS documentation, RCA/CAPA, statistical analysis (MSA, Cp/Cpk), and SPC; working knowledge of ERP/MES and Minitab/Excel.
• Clear written/verbal communication; ability to coach operators, manage audits, and interface with customers and TPI bodies.
Key Performance Indicators (KPIs):
• First-pass yield at critical stages and final test
• Supplier PPM and on-time NCR closure
• Defect/rework reduction (%), COPQ trend
• Calibration compliance and audit scores
• On-time documentation pack readiness and shipment clearance
Why Join Ayr Energy:
Be part of a fast-growing grid hardware company building mission-critical products. You will shape world-class manufacturing systems, work with global suppliers and utilities, and grow into leadership roles with clear impact on reliability and safety of power networks.
Work Conditions:
• Primarily shop-floor based role with regular presence in test bay and oil processing areas.
• Shift and weekend support during critical builds or customer inspections as needed.
• Travel up to 60% for supplier audits, customer FATs, or type test witnessing.
Ayr designs and manufactures critical power grid equipment including power transformers, distribution transformers, special-purpose transformers, high-voltage circuit breakers, and medium-voltage switchgear. They serve markets such as renewables, data centers, utilities, oil & gas, and industrial sectors. They position themselves as partners in power projects, offering lifecycle support and working to deliver faster than average industry timelines.
Website: https://ayr.energy